Analysis of melt ejection during long pulsed laser drilling

In pulsed laser drilling, melt ejection greatly influences the keyhole shape and its quality as well, but its mechanism has not been well understood. In this paper, numerical simulation and experimental investigations based on 304 stainless steel and aluminum targets are performed to study the effects of material parameters on melt ejection. The numerical method is employed to predict the temperatures, velocity fields in the solid, liquid, and vapour front, and melt pool dynamics of targets as well. The experimental methods include the shadow-graphic technique, weight method, and optical microscope imaging, which are applied to real-time observations of melt ejection phenomena, measurements of collected melt and changes of target mass, observations of surface morphology and the cross-section of the keyhole, respectively. Numerical and experimental results show that the metallic material with high thermal diffusivity like aluminum is prone to have a thick liquid zone and a large quantity of melt ejection. Additionally, to the best of our knowledge, the liquid zone is used to illustrate the relations between melt ejection and material thermal diffusivity for the first time. The research result in this paper is useful for manufacturing optimization and quality control in laser-material interaction.     

The influence of temporal pulse train modulation during laser percussion drilling

The temporal pulse train modulation during laser percussion drilling was found to effect significant changes to the material ejection processes. In particular, distinct differences in the material ejection processes have been observed between a temporal pulse train shaping technique termed as sequential pulse delivery pattern control (SPDPC) and the normal delivery pattern (NDP), wherein the parameters of successive laser pulses were constant. Due to the reduced upward material removal fractions in SPDPC drilling, the spatter deposition area was reduced from approximately 6.7 to 2.7 mm². In addition, the melt layer thicknesses at the hole bottom were significantly increased from 11–61 to 18–369 μm. Such changes were identified as being due to the low laser pulse intensities before beam breakthrough associated with the SPDPC method. It was observed that the use of the linearly increasing SPDPC method increased the downward material removal fractions, from 20% to 28% observed in NDP drilling, to 34%–39%. Such an increase in the downward material ejection mechanism in SPDPC drilling was identified as being primarily due to the pointed blind-hole profile generated before the onset of beam breakthrough. The work has shown that modulating the entire pulse train in laser percussion drilling could control the material ejection processes. Furthermore, the fundamental elements of the SPDPC technique are given in terms of the rate of energy deposition and total pulse train energy.     

Laser cutting of polymeric materials: An experimental investigation

The CO₂ laser cutting of three polymeric materials namely polypropylene (PP), polycarbonate (PC) and polymethyl methacrylate (PMMA) is investigated with the aim of evaluating the effect of the main input laser cutting parameters (laser power, cutting speed and compressed air pressure) on laser cutting quality of the different polymers and developing model equations relating input process parameters with the output. The output quality characteristics examined were heat affected zone (HAZ), surface roughness and dimensional accuracy. Twelve sets of tests were carried out for each of the polymer based on the central composite design. Predictive models have been developed by response surface methodology (RSM). First-order response models for HAZ and surface roughness were presented and their adequacy was tested by analysis of variance (ANOVA). It was found that the response is well modeled by a linear function of the input parameters. Response surface contours of HAZ and surface roughness were generated. Mathematical model equations have been presented that estimate HAZ and surface roughness for various input laser cutting parameters. Dimensional accuracies of laser cutting on polymers were examined by dimensional deviation of the actual value from the nominal value. From the analysis, it has been observed that PMMA has less HAZ, followed by PC and PP. For surface roughness, PMMA has better cut edge surface quality than PP and PC. The response models developed can be used for practical purposes by the manufacturing industry. However, all three polymeric materials showed similar diameter errors tendency in spite of different material properties.     

A power ramped pulsed mode laser piercing technique for improved CO2 laser profile cutting

Laser piercing is one of the inevitable requirements of laser profile cutting process and it has a direct bearing on the quality of the laser cut profiles. We have developed a novel power ramped pulsed mode (PRPM) laser piercing technique to produce much finer pierced holes and to achieve a better control on the process parameters compared to the existing methodology based on normal pulsed mode (NPM). Experiments were carried out with both PRPM and NPM laser piercing on 1.5-mm-thick mild steel using an in-house developed high-power transverse flow continuous wave (CW)-CO₂ laser. Significant improvements in the spatter, circularity of the pierced hole and reproducibility were achieved through the PRPM technique. We studied, in detail, the dynamics of processes involved in PRPM laser piercing and compared that with those of the NPM piercing.     

Design and operation characteristics of a high power transverse flow pulser sustained cw CO2 laser

A transverse flow, transverse discharge cw CO₂ laser in which de discharge is sustained by employing high repetition rate high voltage pulses has been developed. Pulser sustained discharge through electrodes of innovative design provided uniform excitation at electrical input power densities more than 10 W/cc. Laser output power more than 2.5 kW was obtained in a laser gas mixture consisting of 0.5 mbar of CO₂, 16 mbar of N₂ and 38.5 mbar of He. Design details and operational characteristics of this laser are presented.     

Thermal processes taking place in the bone during CO2 laser irradiation

The present study examines the drilling and heating of a bone due to pulsed CO₂ laser irradiation. To obtain temperature profiles inside and at the surface of the bone, electron-kinetic and Fourier theories are used. The study is extended to include an experimental investigation into the measurement of the penetration speed. This is achieved using a fibre-optic system. In order to reduce the degree of burning around the hole side, helium was used as the assisting gas during drilling. It is found that the penetration speeds predicted from the theory are in good agreement with the experimentally obtained values.     

Nonlinear dynamics of the dual-wavelength CO2 laser

Theoretical studies have been made of the nonlinear-dynamic modes of operation of a dual-wavelength CO₂ laser with continuous pumping by electric discharge and loss modulation in one of the lasing channels. It is shown that by varying the modulation depth and frequency, it is possible to control, over a fairly wide range, the time and energy parameters of lasing in both channels, going from regular to chaotic modes of operation. Translated from Zhurnal Prikladnoi Spektroskopii, Vol. 67, No. 3, pp. 316–321, May–June, 2000.     

High-power transverse flow CW CO2 laser for material processing applications

A transverse flow transversely excited (TFTE) CW CO₂ with a maximum output power about 15 kW has been developed. This is excited by pulser sustained DC discharge applied between a pair of multi-pins anodes and a common tubular cathode. Though the laser power in convective cooled CO₂ laser scales proportionally with the volumetric gas flow, it did not increase in this laser when the volumetric gas flow was increased by increasing the electrode separation keeping the flow velocity constant. The discharge voltage too remained almost unchanged with increase of the electrode separation. These observations are explained considering the electrical discharge being controlled by ionization instability. Laser materials processing applications often demand programming facilities for laser power modulation. A four-stage cascaded multilevel DC–DC converter-based high-frequency switch mode power supply has been developed to modulate the output power of the laser. Laser was operated up to 15 kW output power in four different modes viz. continuous wave mode, pulse periodic mode, single shot mode and processing velocity-dependent power mode with 1.2 kHz modulation bandwidth. We describe briefly the laser system, the SMPS, and the temporal behavior of laser beam.     

CO2 laser cutting of slate

Slate is a natural stone which has the characteristic that shows a well-developed defoliation plane, allowing to easily split it in plates parallel to that plane which are particularly used as tiles for roof building. At present, the manufacturing of slate is mostly manual, being noisy, powdery and unsafe for the worker. Thus, there is a need to introduce new processing methods in order to improve both the working conditions and the quality of the products made of slate.Following the previous work focused on the drilling and cutting of slate tiles using a Nd : YAG laser, we present in this paper the results of the work carried out to explore the possibilities to cut slate plates by using a CO₂ laser. A 1.5 kW CO₂ laser was used to perform different experiments in which, the influence of some processing parameters (average power, assist gas pressure) on the geometry and quality of the cut was studied. The results obtained show that the CO₂ laser is a feasible tool for a successful cutting of slate.     

Theoretical prediction on the wavelength-temperature shift in pulsed TE CO2 lasers

The wavelength-temperature shift observed in pulsed TE CO₂ lasers is discussed theoretically by means of Six-temperature model rate equations for tunable TE CO₂ lasers. Numerical calculations of the temperature-wavelength shift in a pulsed TE CO₂ laser with a simple plano-concave stable resonator, whether excited by conventional low-inductance fast-discharge scheme or by a long-pulse Pulser/sustainer discharge scheme, show that the laser output wavelengths are within the 10P branch as the ambient temperature varies from 228 to 338 K, but will change as the ambient temperature varies. The laser output wavelengths will move to the transition lines with longer wavelengths in the 10P branch as the ambient temperature increases and vice versa. The calculated results also illustrate that near the ambient temperature of 310 K, the laser is more likely to operate on multi-transition lines. Considering this wavelength-temperature shift, the chilling device adopted in high-power high repetition rate TE CO₂ lasers is important in maintaining a stable laser output spectra as well as a stable laser output power. The numerical results also suggest that a frequency agile resonator is highly recommended if stable laser output spectra are required in TE CO₂ lasers.     

Photodissociation dynamics of triatomic molecule in presence of pulsed and bichromatic laser field

The photodissociation dynamics of a triatomic molecule in the presence of pulsed and bichromatic electric field have been investigated. We have considered MgH₂ molecule in its ground state potential energy surface. The time-dependent Fourier Grid Hamiltonian method is invoked to follow the dissociation dynamics as a function of field strength, frequency, phase difference, etc.     

Silver nanoparticles generated by pulsed laser ablation in supercritical CO2 medium

Pulsed laser ablation (PLA) has been widely employed in industrial and biological applications and in other fields. The environmental conditions in which PLA is conducted are important parameters that affect both the solid particle cloud and the deposition produced by the plume. In this work, the generation of nanoparticles (NPs) has been developed by performing PLA of silver (Ag) plates in a supercritical CO₂ medium. Ag NPs were successfully generated by allowing the selective generation of clusters. Laser ablation was performed with an excitation wavelength of 532 nm under various pressures and temperatures of CO₂ medium. On the basis of the experimental result, both surface of the irradiated Ag plate and structure of Ag NPs were significantly affected by the changes in supercritical CO₂ pressure and temperature. With increasing irradiation pressure, plume deposited in the surrounding crater created by the ablation was clearly observed. In Field Emission Scanning Electron Microscopy (FE-SEM) the image of the generated Ag NPs on the silicon wafer and the morphology of Ag particles were basically a sphere-like structure. Ag particles contain NPs with large-varied diameter ranging from 5 nm to 1.2 μm. The bigger Ag NPs melted during the ablation process and then ejected smaller spherical Ag NPs, which formed nanoclusters attached on the molten Ag NPs. The smaller Ag NPs were also formed around the bigger Ag NPs. Based on the results, this new method can also be used to obtain advanced nano-structured materials.     

脉冲CO2激光器的多频动力学模型

建立了适用于各种气压下(20×133—20×10⁵ Pa)的脉冲CO₂激光器的六温度多频动力学模型，该模型考虑了增益谱线重叠效应，序列带、热带的影响，以及非洛伦兹线型效应.对模型进行数值求解可以预言和解释不同气压下的脉冲CO₂激光器的输出特性，有助于评价不同的抽运设计和研究可调谐特性，为设计脉冲CO₂激光系统提供理论支持. 关键词： 2激光器')" href="#">CO₂激光器 激光动力学 六温度模型 增益谱线重叠     

Effect of leakage transformer on laser power and mode pattern of CO2 laser excited by 60 Hz AC discharges

The 60 Hz AC discharges generated by a leakage transformer instead of an isolation one, which is usually used in the power supply of DC CO₂ laser, are employed as a pumping source in this experiment. The laser performance characteristics as functions of pressure and discharge current have been investigated. The maximum laser power is about 40 W at conditions of 18 Torr and 35 mA. The output power is not less than that of DC discharge at the same condition. In addition, the laser outputs of 60 Hz AC discharges obtained by different transformers such as a leakage type and an isolation one have been measured. It was found that the laser power obtained by the leakage transformer is saturated at the higher current compared with the isolation transformer.     

Design and experimental characterisation of a DC-excited CW/repetitively pulsed sealed off CO2 laser

This paper reports the design procedure and experimental study of a sealed off CO₂ laser. Simple algorithms for threshold and steady state excitation voltage calculation, resonator design and its temperature dependent operation are presented. The sealed off CO₂ laser was operated both in CW and pulsed modes and found stable both thermodynamically and optically. Frequency limits for pulsed operation regarding maximum and minimum output energy ranges are determined. Different aspects of CO₂ laser studied include threshold excitation voltages, temperature dependent efficiency, optical power saturation limitations, pulsed and steady state discharge currents for optimum gases mixture combinations. The laser has successfully been constructed, operated and tested for different applications within the limits of its maximum output power of 14 W.     

A scribing laser marking system using DSP controller

Laser marking is an important branch of laser processing technology, and has been widely used in many fields of industry. Digital signal processor (DSP) is an incredibly fast and powerful microprocessor that can deal with signals in real time. Not only it is portable but has the ability to integrate the processing signals of subsystems. In this research, it is emphasized that we designed a scribing laser marking system based on a DSP in galvanometric marking method. To control the rotating angle of the galvanometric scanning mirrors more accurately, we combine the D/A converter of the DSP with the human–machine interface successfully. The whole marking system is not only inexpensive, but also miniaturized.     

The power dependence of a carbon-dioxide laser on the gas flow

Summary The gas flow rate has resulted very important to get high power in a CO₂ diffusion-cooled laser. Some measurements suggest that the power dependence on the flow is connected with the chemical dissociation of the components of the gas mixture. Four different gas circuits have been experimented. To speed up publication, the authors of this paper have agreed to not receive the proofs for correction.     

Surface treatment with linearly polarized laser beam at oblique incidence

An effective method for surface heat treatment with 10.6 μm linear polarized laser beam at oblique incidence is reported. A circular focused laser spot on the workpiece surface, simultaneously with 2.2–4 times increasing of the absorption are obtained in the 70–80° range of the incidence angle. The main element of the experimental setup is the astigmatic focusing head which focalize the laser beam into an elliptical spot of ellipticity >3 at normal incidence. At a proper incidence angle (obtained by the focusing head tilting) the focused laser spot on the work piece surface gets a circular form and p-state of polarization is achieved.We performed laser heat treatment (transformation hardening, surface remelting) of the uncoated surface, as well as the alloying and cladding processes by powder injection. An enhancement of the processing efficiency was obtained; in this way the investment and operation costs for surface treatment with CO₂ laser can be significantly reduced. Several technical advantages concerning the pollution of the focusing optical components, powder jet flowing and reflected radiation by the work piece surface are obtained.     

Numerical investigation of a fast-axial-flow CW CO2 laser

This paper presents the results of the calculation of the parameters of the active medium of a fast-axial-flow CO₂ laser using numerical methods in the framework of a one-dimensional approximation of the set of continuity equations, Bernoulli equation, equation of gas state, energy equation and multi-temperature rate equations with regard to diffusion for the gas flow in the cylindrical discharge tube. The spatial distribution of the small-signal gain and gas temperature along the gas flow direction have been calculated for a given set of initial conditions, namely, gas flow velocity, gas pressure and the tube diameter. In addition, the dependence of small-signal gain, the asymmetric stretch vibrational temperature of CO₂ (T₃) and the gas temperature on the discharge current were studied.     

Numerical modeling of a fast-axial-flow CW–CO2 laser

A four-temperature model has been applied on a fast axial flow, longitudinal discharge CO₂ laser. Using Runge–Kutta method, a set of differential equations of the model is numericaly solved. These equations describe the operation of the laser with certain ratio 1:3:6 of the mixture CO₂:N₂: He and average output power of 550 W.The temporal behaviour of the output power and photon density was obtained. The effects of kinetic temperature, coupled mirror reflectivity, gas flow speed, and cavity loss on the output power were studied.Calculated output power was compared with its measured value taken from experiment and a good agreement was observed.